Aerosol generation

ABSTRACT

A method of manufacturing an aerosol-generating material having a shredded amorphous solid, the method including: (a) forming a layer of a slurry comprising: 1-60 wt % of a gelling agent; 0.1-50 wt % of an aerosol-former material; 5-50 wt % of filler in the form of fibers; and 0.1-80 wt % of a flavorant and/or active substance; wherein these weights are calculated on a dry weight basis; (b) drying the slurry to provide the amorphous solid; and (c) shredding the amorphous solid to provide the shredded amorphous solid.

PRIORITY CLAIM

The present application is a National Phase entry of PCT Application No.PCT/EP2021/072597, filed Aug. 13, 2021, which claims priority from GBApplication No. 2012747.8, filed Aug. 14, 2020, each of which are herebyfully incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to methods of manufacturing anaerosol-generating material, aerosol-generating materials comprising anamorphous solid, consumables for use within a non-combustible aerosolprovision system, the consumables comprising the aerosol-generatingmaterial comprising the amorphous solid; and non-combustible aerosolprovision systems.

BACKGROUND

Smoking consumables such as cigarettes, cigars and the like burn tobaccoduring use to create tobacco smoke. Alternatives to these types ofconsumables release an inhalable aerosol or vapor by releasing compoundsfrom a substrate material by heating without burning. These may bereferred to as non-combustible smoking consumables or aerosol generatingassemblies.

One example of such a product is a heating device which releasescompounds by heating, but not burning, a solid aerosol-generatingmaterial. This solid aerosol-generating material may, in some cases,contain a botanical material. The heating volatilizes at least onecomponent of the material, typically forming an inhalable aerosol. Theseproducts may be referred to as heat-not-burn devices, tobacco heatingdevices or tobacco heating products. Various different arrangements forvolatilizing at least one component of the solid aerosol-generatingmaterial are known.

As another example, there are hybrid devices. These contain a liquidsource (which may or may not contain nicotine) which is vaporized byheating to produce an inhalable vapor or aerosol. The deviceadditionally contains a solid aerosol-generating material (which may ormay not contain a tobacco material) and components of this material areentrained in the inhalable vapor or aerosol to produce the inhaledmedium.

SUMMARY

According to a first aspect of the present invention, there is provideda method of manufacturing an aerosol-generating material comprising ashredded amorphous solid, the method comprising:

-   -   a) forming a layer of a slurry comprising:        -   1-60 wt % of a gelling agent;        -   0.1-50 wt % of an aerosol-former material; and        -   5-50% of filler in the form of fibers; and        -   0.1-80 wt % of a flavorant and/or active substance;    -    wherein these weights are calculated on a dry weight basis,    -   b) drying the slurry to provide the amorphous solid; and    -   c) shredding the amorphous solid to provide the shredded        amorphous solid.

In a further aspect the invention provides an aerosol-generatingmaterial comprising an amorphous solid, wherein the amorphous solidcomprises:

-   -   1-60 wt % of a gelling agent;    -   0.1-50 wt % of an aerosol-former material;    -   5-50% of filler in the form of fibers; and    -   0.1-80 wt % of a flavorant and/or active substance,

wherein these weights are calculated on a dry weight basis,

wherein the amorphous solid is in the form of shreds.

In a further aspect the invention provides an aerosol-generatingmaterial obtainable by using the method as described herein.

In a still further aspect the invention provides a consumable for usewith a non-combustible aerosol provision system, comprising the aerosolgenerating material as defined elsewhere herein.

In a further aspect the invention provides a non-combustible aerosolprovision system comprising the consumable as defined elsewhere hereinand a non-combustible aerosol provision device, the non-combustibleaerosol provision device comprising an aerosol-generation devicearranged to generate aerosol from the consumable when the consumable isused with the non-combustible aerosol provision device.

Also provided by the invention is the use of an aerosol-generatingmaterial as defined elsewhere herein in a consumable for use with anon-combustible aerosol provision device, the non-combustible aerosolprovision device comprising an aerosol-generation device arranged togenerate aerosol from the consumable when the consumable is used withthe non-combustible aerosol provision device.

To the extent that they are combinable, features described herein inrelation to one aspect of the invention are explicitly disclosed incombination with each and every other aspect.

Further features and advantages of the invention will become apparentfrom the following description of preferred embodiments of theinvention, given by way of example only, which is made with reference tothe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a section view of an example of a consumable.

FIG. 2 shows a perspective view of the consumable of FIG. 1 .

FIG. 3 shows a sectional elevation of an example of a consumable.

FIG. 4 shows a perspective view of the consumable of FIG. 3 .

FIG. 5 shows a perspective view of an example of a non-combustibleaerosol provision system.

FIG. 6 shows a section view of an example of a non-combustible aerosolprovision system.

FIG. 7 shows a perspective view of an example of a non-combustibleaerosol provision system.

FIG. 8 shows a flow diagram of an exemplary method of the invention.

DETAILED DESCRIPTION

Suitably the aerosol-generating material produced by the method of theinvention is in the form of an aerosol forming “amorphous solid”. Theaerosol-forming “amorphous solid” may alternatively be referred to as a“monolithic solid” (i.e. non-fibrous), or as a “dried gel”. Theamorphous solid is a solid material that may retain some fluid, such asliquid, within it. The amorphous solid may form part of anaerosol-generating material which comprises from 50 wt %, 60 wt % or 70wt % of amorphous solid, to about 90 wt %, 95 wt % or 100 wt % ofamorphous solid. In some cases, the aerosol-generating material consistsof amorphous solid.

The amorphous solid of the aerosol-generating material describedthroughout is formed from a dried gel. The inventors have found thatusing the component proportions described herein means that as the gelsets, flavor compounds are stabilized within the gel matrix allowing ahigher flavor loading to be achieved than in non-gel compositions. Theflavoring (e.g. menthol) is stabilized at high concentrations and theproducts have a good shelf life.

In some cases, the amorphous solid comprises 5-50 wt %, 10-40 wt % or15-30 wt % of the filler. In some such cases the amorphous solidcomprises at least 1 wt % of the filler, for example, at least 5 wt %,at least 10 wt %, at least 20 wt % at least 30 wt %, at least 40 wt %,or at least 50 wt % of a filler. In exemplary embodiments the amorphoussolid comprises from 5-25 wt % of a filler comprising fibers. Suitablythe filler consists of fibers, or is in the form of fibers.

In some embodiments, the amorphous solid comprises less than 60 wt % ofthe filler, such as from 1 wt % to 60 wt %, or 5 wt % to 50 wt %, or 5wt % to 30 wt %, or 10 wt % to 20 wt %.

In some embodiments, the amorphous solid comprises less than 60 wt % ofthe filler, such as from 1 wt % to 60 wt %, or 5 wt % to 50 wt %, or 5wt % to 30 wt %, or 10 wt % to 20 wt %.

In other embodiments, the amorphous solid comprises less than 20 wt %,suitably less than 10 wt % or less than 5 wt % of the filler.

The filler may comprise one or more organic filler materials such aswood pulp, cellulose and cellulose derivatives (such as methylcellulose,hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)). Inparticular cases, the amorphous solid comprises no calcium carbonatesuch as chalk.

Suitably, the filler is fibrous. For example, the filler may be afibrous organic filler material such as wood pulp, hemp fiber, celluloseor cellulose derivatives (such as methylcellulose, hydroxypropylcellulose, and carboxymethyl cellulose (CMC)). Without wishing to bebound by theory, it is believed that including fibrous filler in anamorphous solid may increase the tensile strength of the material.Additionally, including a fibrous filler has been found to improve thehandling of the amorphous solid during manufacturing. In particular, ithas been found that the resulting amorphous solid is less “tacky” andconsequently is easier to shred during manufacturing. Including afibrous filler can therefore increase manufacturing efficiency, reducingthe likelihood of machine stops during shredding. Including a fibrousfiller in the amorphous solid also means that the amorphous solid isless likely to clump together (e.g. agglomerate) once it has beenshredded. When the shredded amorphous solid is included in consumables,reduced agglomeration optimizes the distribution of the shreddedamorphous solid in the consumables. It is therefore more likely thateach consumable will contain a similar quantity of shredded amorphoussolid, which may improve homogeneity of the flavorant loading withinbatches of consumables and/or within a given consumable.

As noted above, the present invention thus provides a method ofmanufacturing an aerosol-generating material comprising a shreddedamorphous solid, the method comprising:

-   -   a) forming a layer of a slurry comprising:        -   1-60 wt % of a gelling agent;        -   0.1-50 wt % of an aerosol-former material; and        -   5-50% of filler in the form of fibers; and        -   0.1-80 wt % of a flavorant and/or active substance;        -   wherein these weights are calculated on a dry weight basis,    -   b) drying the slurry to provide the amorphous solid; and    -   c) shredding the amorphous solid to provide the shredded        amorphous solid.

In some embodiments drying the slurry to provide the amorphous solidresults in forming a sheet of amorphous solid. Suitably the sheet ofamorphous solid may be wound onto a bobbin or cut into flags which mayfacilitate transport or storage. In some such embodiments, the amorphoussolid sheet is unwound from the bobbin and then shredded. Suitably theshredded amorphous solid is then incorporated into consumables which aredescribed elsewhere herein.

An amorphous solid which contains fibrous filler is typically moresuited to transport and long-term packaging, and allows forsimplification of the manufacturing process of a consumable. Portions ofamorphous solid which contact each other (e.g. a stack of flags ofamorphous solid, or adjoining portions of amorphous solid wound on abobbin) that do not contain a fibrous filler may be compacted togetherduring storage, meaning that a step of separating the portions ofamorphous solid must be carried out before the portions can be processedfor including in a consumable (e.g. the portions of amorphous solid aremanually separated). In contrast, portions of amorphous solid whichcontain a fibrous filler are typically more resilient during storage andtransport such that they may be processed without a costly andtime-consuming manual separation step (e.g. they can be fed directlyinto the machinery from a stack of flags or from a bobbin).

Suitably, the slurry and/or amorphous solid comprises from about 1 wt %,5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 60 wt %, 50 wt %,45 wt %, 40 wt % or 35 wt % of a gelling agent (all calculated on a dryweight basis). For example, the slurry and/or amorphous solid maycomprise 1-50 wt %, 5-45 wt %, 10-40 wt % or 20-35 wt % of a gellingagent. In exemplary embodiments, the slurry and/or amorphous solidcomprises from about 20 wt % 22 wt %, 24 wt % or 25 wt % to about 30 wt%, 32 wt % or 35 wt % of a gelling agent (all calculated on a dry weightbasis). For example, the slurry and/or amorphous solid comprises 20-35wt % or 25-30 wt % of a gelling agent.

In some embodiments, the gelling agent comprises one or more compoundsselected from the group comprising alginates, pectins, starches (andderivatives), celluloses (and derivatives), gums, silica or siliconescompounds, clays, polyvinyl alcohol and combinations thereof. Forexample, in some embodiments, the gelling agent comprises one or more ofalginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose,carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan,agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin andpolyvinyl alcohol. In some embodiments, the gelling agent comprises ahydrocolloid. In some cases, the gelling agent comprises alginate and/orpectin, and may be combined with a setting agent (such as a calciumsource) during formation of the amorphous solid. In some cases, theamorphous solid may comprise a calcium-crosslinked alginate and/or acalcium-crosslinked pectin.

In some embodiments, the gelling agent comprises alginate, and thealginate is present in the slurry and/or amorphous solid in an amount offrom 10-30 wt %, 20-35 wt % or 25-30 wt % of the slurry/amorphous solid(calculated on a dry weight basis). In some embodiments, alginate is theonly gelling agent present in the slurry and/or amorphous solid. Inother embodiments, the gelling agent comprises alginate and at least onefurther gelling agent, such as pectin.

In some embodiments, the method further comprises applying setting agentto the layer of slurry. In some embodiments, the setting agent is acalcium solution. In some of these embodiments, the calcium solution isa calcium lactate solution. In further such embodiments the calciumsolution is sprayed onto the layer of slurry.

In some embodiments, the slurry and/or amorphous solid may includegelling agent comprising carrageenan.

The inclusion of a gelling agent in the slurry results in theaerosol-generating material being formed from a dried gel. The inventorshave found that by including a gel in the aerosol-generating material,flavorant compounds, for example, menthol, are stabilized within the gelmatrix allowing a higher flavorant loading to be achieved than innon-gel compositions. The flavoring (e.g. menthol) is stabilized at highconcentrations and the products have a good shelf life.

Suitably, the slurry and/or amorphous solid comprises about 0.1 wt %,0.5 wt %, 1 wt %, 3 wt %, 5 wt %, 7 wt % or 10% to about 50 wt %, 45 wt%, 40 wt %, 35 wt %, 30 wt % or 25 wt % of an aerosol-former material(all calculated on a dry weight basis). In exemplary embodiments, theslurry and/or amorphous solid comprises from 10-25 wt % of anaerosol-former material. The aerosol-former material may act as aplasticizer. In some cases, the aerosol-former material comprises one ormore compound selected from erythritol, propylene glycol, glycerol,triacetin, sorbitol and xylitol. In some cases, the aerosol-formermaterial comprises, consists essentially of, or consists of glycerol.The inventors have established that if the content of the plasticizer istoo high, the amorphous solid may absorb water resulting in a materialthat does not create an appropriate consumption experience in use. Theinventors have established that if the plasticizer content is too low,the amorphous solid may be brittle and easily broken. The plasticizercontent specified herein provides an amorphous solid flexibility whichallows the sheet to be wound onto a bobbin, which is useful inmanufacture of consumables or can allow the sheet to be transportedprior to shredding.

In some embodiments, the slurry and/or amorphous solid may comprise upto about 80 wt %, 70 wt %, 60 wt %, 55 wt %, 50 wt % or 45 wt % offlavorant. In some cases, the slurry and/or amorphous solid may compriseat least about 0.1 wt %, 1 wt %, 10 wt %, 20 wt %, 30 wt %, 35 wt % or40 wt % of flavorant (all calculated on a dry weight basis). Forexample, the slurry and/or amorphous solid may comprise 1-80 wt %, 10-80wt %, 20-70 wt %, 30-60 wt %, 35-55 wt % or 30-45 wt % of flavorant. Inexemplary embodiments, the slurry and/or amorphous solid comprises 35-50wt % of flavorant. In some cases, the flavorant comprises, consistsessentially of or consists of menthol.

In some embodiments, the slurry and/or amorphous solid alternatively oradditionally comprises an active substance. For example, in some cases,the slurry and/or amorphous solid additionally comprises a tobaccomaterial and/or nicotine. In some cases, the slurry and/or amorphoussolid may comprise 5-60 wt % (calculated on a dry weight basis) of atobacco material and/or nicotine. In some cases, the slurry and/oramorphous solid may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt%, 20 wt % or 25 wt % to about 70 wt %, 60 wt %, 50 wt %, 45 wt %, 40 wt%, 35 wt %, or 30 wt % (calculated on a dry weight basis) of an activesubstance. In some cases, the slurry and/or amorphous solid may comprisefrom about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about70 wt %, 60 wt %, 50 wt %, 45 wt %, 40 wt %, 35 wt %, or 30 wt %(calculated on a dry weight basis) of a tobacco material. For example,the slurry and/or amorphous solid may comprise 10-50 wt %, 15-40 wt % or20-35 wt % of a tobacco material. In some cases, the slurry and/oramorphous solid may comprise from about 1 wt %, 2 wt %, 3 wt % or 4 wt %to about 20 wt %, 18 wt %, 15 wt % or 12 wt % (calculated on a dryweight basis) of nicotine. For example, the slurry and/or amorphoussolid may comprise 1-20 wt %, 2-18 wt % or 3-12 wt % of nicotine.

In some cases, the slurry and/or amorphous solid comprises an activesubstance such as tobacco extract. In some cases, the slurry and/oramorphous solid may comprise 5-60 wt % (calculated on a dry weightbasis) of tobacco extract. In some cases, the slurry and/or amorphoussolid may comprise from about 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt% to about 60 wt %, 50 wt %, 45 wt %, 40 wt %, 35 wt %, or 30 wt %(calculated on a dry weight basis) tobacco extract. For example, theslurry and/or amorphous solid may comprise 10-50 wt %, 15-40 wt % or20-35 wt % of tobacco extract. The tobacco extract may contain nicotineat a concentration such that the slurry and/or amorphous solid comprises1 wt % 1.5 wt %, 2 wt % or 2.5 wt % to about 6 wt %, 5 wt %, 4.5 wt % or4 wt % (calculated on a dry weight basis) of nicotine. In some cases,there may be no nicotine in the amorphous solid other than that whichresults from the tobacco extract.

In some embodiments the slurry and/or amorphous solid comprises notobacco material but does comprise nicotine. In some such cases, theslurry and/or amorphous solid may comprise from about 1 wt %, 2 wt %, 3wt % or 4 wt % to about 20 wt %, 18 wt %, 15 wt % or 12 wt % (calculatedon a dry weight basis) of nicotine. For example, the slurry and/oramorphous solid may comprise 1-20 wt %, 2-18 wt % or 3-12 wt % ofnicotine.

In some cases, the total content of active substance and/or flavorantmay be at least about 0.1 wt %, 1 wt %, 5 wt %, 10 wt %, 20 wt %, 25 wt% or 30 wt % of the slurry and/or amorphous solid. In some cases, thetotal content of active substance and/or flavorant may be less thanabout 90 wt %, 80 wt %, 70 wt %, 60 wt %, 50 wt % or 40 wt % (allcalculated on a dry weight basis).

In some cases, the slurry and/or amorphous solid may additionallycomprise an emulsifying agent, which emulsifies flavorant duringmanufacture. For example, the slurry and/or amorphous solid may comprisefrom about 5 wt % to about 15 wt % of an emulsifying agent (calculatedon a dry weight basis), suitably about 10 wt %. The emulsifying agentmay comprise acacia gum.

In some embodiments, the amorphous solid is a hydrogel and comprisesless than about 20 wt % of water calculated on a wet weight basis. Insome cases, the hydrogel may comprise less than about 15 wt %, 12 wt %or 10 wt % of water calculated on a wet weight basis. In some cases, thehydrogel may comprise at least about 1 wt %, 2 wt % or at least about 5wt % of water (WWB).

In some embodiments the slurry comprises:

-   -   20-35 wt % of the gelling agent;    -   10-25 wt % of the aerosol-former material;    -   5-25 wt % of the filler in the form of fibers;    -   35-50 wt % of the flavorant and/or the active substance    -   wherein these weights are calculated on a dry weight basis.        In some embodiments the amorphous solid comprises:    -   20-35 wt % of the gelling agent;    -   10-25 wt % of the aerosol-former material;    -   5-25 wt % of the filler in the form of fibers;    -   35-50 wt % of the flavorant and/or active substance    -   wherein these weights are calculated on a dry weight basis.

In some cases, the aerosol-generating material may have a thickness ofabout 0.015 mm to about 1.0 mm. Suitably, the thickness may be in therange of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. Theinventors have found that a material having a thickness of 0.2 mm isparticularly suitable. The aerosol-generating material may comprise morethan one layer, and the thickness described herein refers to theaggregate thickness of those layers.

In some cases, the amorphous solid may have a thickness of about 0.015mm to about 1.0 mm. Suitably, the thickness may be in the range of about0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors havefound that a material having a thickness of 0.2 mm is particularlysuitable. The amorphous solid may comprise more than one layer, and thethickness described herein refers to the aggregate thickness of thoselayers.

The inventors have established that if the aerosol-generating materialor amorphous solid is too thick, then heating efficiency is compromised.This adversely affects the power consumption in use. Conversely, if theaerosol-generating material or amorphous solid is too thin, it isdifficult to manufacture and handle; a very thin material is harder tocast and may be fragile, compromising aerosol formation in use.

The inventors have established that the aerosol-generating materialthicknesses stipulated herein optimize the material properties in viewof these competing considerations.

The thickness stipulated herein is a mean thickness for the material. Insome cases, the amorphous solid thickness may vary by no more than 25%,20%, 15%, 10%, 5% or 1%.

In some embodiments, consumables comprise an aerosol-generating materialas described herein, wherein the amorphous solid is in the form ofshreds. In such embodiments, the amorphous solid may be formed from asheet which has been shredded. In exemplary consumables, theaerosol-generating material comprises amorphous solid which is shreddedand mixed with a shredded tobacco material, e.g. the aerosol-generatingmaterial comprises a blend of shredded amorphous solid and tobaccomaterial. In some examples where the tobacco material is fine cut andthe aerosol-generating material is a shredded sheet, the cut width ofthe amorphous solid is from about 90 to 110% of the cut width of thetobacco material. That is, the aerosol-generating material comprisingthe amorphous solid and the tobacco material have similar cut widths, orshred widths. The inventors have identified that configuring theamorphous solid and tobacco material to have similar cut widths allowsfor better blending of the amorphous solid and tobacco material. Forexample, shredded amorphous solid sheet and cut rag tobacco which havesimilar cut widths can be blended to provide a more homogenousaerosol-generating composition (e.g. better distribution of eachcomponent throughout the aerosol-generating composition).

In examples, the amorphous solid has an area density which is from about90 to 110% of the area density of the tobacco material. That is, theamorphous solid and the tobacco material have similar area densities.The inventors have identified that configuring the amorphous solid andtobacco material to have similar area densities allows for betterblending of the amorphous solid and tobacco material, typically whenprovided as shredded sheet. For example, shredded amorphous solid sheetand cut rag tobacco which have similar area densities can be blended toprovide a more homogenous aerosol-generating composition (e.g. betterdistribution of each component throughout the aerosol-generatingcomposition).

In some examples, the amorphous solid in sheet form may have a tensilestrength of from around 200 N/m to around 900 N/m. In some examples, theamorphous solid may have a tensile strength of from 600 N/m to 900 N/m,or from 700 N/m to 900 N/m, or around 800 N/m. Such tensile strengthsmay be particularly suitable for embodiments wherein theaerosol-generating material is formed as a sheet and then shredded andincorporated into an aerosol-generating consumable.

In some cases, the amorphous solid may consist essentially of, orconsist of a gelling agent, water, an aerosol-former material, a flavor,and optionally an active substance.

In some cases, the amorphous solid may consist essentially of, orconsist of a gelling agent, water, an aerosol-former material, a flavor,and optionally a tobacco material and/or a nicotine source.

In some embodiments of the method, the layer of slurry has a thicknessof about 0.015 mm to about 2.0 mm, suitably about 0.05 mm to about 1.5mm or 0.05 mm to about 1.0 mm. Suitably, the thickness may be in therange of from about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm or 0.3 mm.The inventors have found that a material having a thickness of 0.2 mm isparticularly suitable.

The inventors have established that if the amorphous solid is too thick,then heating efficiency is compromised. This adversely affects the powerconsumption in use. Conversely, if the amorphous solid is too thin, itis difficult to manufacture and handle; a very thin material is harderto cast and may be fragile, compromising aerosol formation in use. Theinventors have established that the amorphous solid thicknessesstipulated herein optimize the material properties in view of thesecompeting considerations.

The thickness values stipulated herein are mean values for the thicknessin question. In some cases, the thickness may vary by no more than 25%,20%, 15%, 10%, 5% or 1%.

The aerosol-generating material comprising the amorphous solid may haveany suitable area density, such as from 30 g/m² to 120 g/m². In somecases, the sheet may have a mass per unit area of 80-120 g/m², or fromabout 70 to 110 g/m², or particularly from about 90 to 110 g/m², orsuitably about 100 g/m² (so that it has a similar density to cut ragtobacco and a mixture of these substances will not readily separate).Such area densities may be particularly suitable where theaerosol-generating material is included in a consumable/assembly as ashredded sheet (described further hereinbelow). In some cases, the sheetmay have a mass per unit area of about 30 to 70 g/m², 40 to 60 g/m², or25-60 g/m².

Consumable and Non-Combustible Aerosol Provision System

As used herein, the term “delivery system” is intended to encompasssystems that deliver a substance to a user, and includes:

-   -   combustible aerosol provision systems, such as cigarettes,        cigarillos, cigars, and tobacco for pipes or for roll-your-own        or for make-your-own cigarettes (whether based on tobacco,        tobacco derivatives, expanded tobacco, reconstituted tobacco,        tobacco substitutes or other smokable material);    -   non-combustible aerosol provision systems that release compounds        from an aerosol-generating material without combusting the        aerosol-generating material, such as electronic cigarettes,        tobacco heating products, and hybrid systems to generate aerosol        using a combination of aerosol-generating materials;    -   consumables comprising aerosol-generating material and        configured to be used within one of these non-combustible        aerosol provision systems; and    -   aerosol-free delivery systems which deliver one or more        substances to a user orally, nasally, transdermally or in        another way without forming an aerosol, including but not        limited to, lozenges, gums, patches, consumables comprising        inhalable powders, and oral products such as oral tobacco which        includes snus or moist snuff, wherein the substance may or may        not comprise nicotine.

According to the present disclosure, a “combustible” aerosol provisionsystem is one where a constituent aerosol-generating material of theaerosol provision system (or component thereof) is combusted or burnedduring use in order to facilitate delivery to a user.

According to the present disclosure, a “non-combustible” aerosolprovision system is one where a constituent aerosol-generating materialof the aerosol provision system (or component thereof) is not combustedor burned in order to facilitate delivery to a user.

In some embodiments, the delivery system is a combustible aerosolprovision system, selected from the group consisting of a cigarette, acigarillo and a cigar.

In some embodiments, the disclosure relates to a component for use in acombustible aerosol provision systems, such as a filter, a filter rod, afilter segment, a tobacco rod, a spill, an additive release componentsuch as a capsule, a thread, or a bead, or a paper such as a plug wrap,a tipping paper or a cigarette paper.

In some embodiments, the delivery system is a non-combustible aerosolprovision system, such as a powered non-combustible aerosol provisionsystem.

In some embodiments, the non-combustible aerosol provision system is anelectronic cigarette, also known as a vaping device or electronicnicotine delivery system (END), although it is noted that the presenceof nicotine in the aerosol-generating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is atobacco heating system, also known as a heat-not-burn system.

In some embodiments, the non-combustible aerosol provision system is ahybrid system to generate aerosol using a combination ofaerosol-generating materials, one or a plurality of which may be heated.Each of the aerosol-generating materials may be, for example, in theform of a solid, liquid or gel and may or may not contain nicotine. Insome embodiments, the hybrid system comprises a liquid or gelaerosol-generating material and a solid aerosol-generating material. Thesolid aerosol-generating material may comprise, for example, tobacco ora non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise anon-combustible aerosol provision device and a consumable for use withthe non-combustible aerosol provision device. However, it is envisagedthat consumables which themselves comprise a means for powering anaerosol generating component may themselves form the non-combustibleaerosol provision system.

In some embodiments, the non-combustible aerosol provision device maycomprise a power source and a controller. The power source may, forexample, be an electric power source or an exothermic power source. Insome embodiments, the exothermic power source comprises a carbonsubstrate which may be energized so as to distribute power in the formof heat to an aerosol-generating material or heat transfer material inproximity to the exothermic power source. In some embodiments, the powersource, such as an exothermic power source, is provided in theconsumable so as to form the non-combustible aerosol provision.

In some embodiments, the consumable for use with the non-combustibleaerosol provision device may comprise an aerosol-generating material, anaerosol generating component, an aerosol generating area, a mouthpiece,and/or an area for receiving aerosol-generating material.

In some embodiments, the aerosol generating component is a heatercapable of interacting with the aerosol-generating material so as torelease one or more volatiles from the aerosol-generating material toform an aerosol. In some embodiments, the aerosol generating componentis capable of generating an aerosol from the aerosol-generating materialwithout heating. For example, the aerosol generating component may becapable of generating an aerosol from the aerosol-generating materialwithout applying heat thereto, for example via one or more ofvibrational, mechanical, pressurization or electrostatic means.

The consumable may alternatively be referred to herein as a cartridge.The consumable may be adapted for use in a THP, a hybrid device oranother aerosol generating device. In some cases, the consumable mayadditionally comprise a filter and/or cooling element, as describedpreviously. In some cases, the consumable may be circumscribed by awrapping material such as paper.

The consumable may additionally comprise ventilation apertures. Thesemay be provided in the sidewall of the consumable. In some cases, theventilation apertures may be provided in the filter and/or coolingelement. These apertures may allow cool air to be drawn into theconsumable during use, which can mix with the heated volatilisedcomponents thereby cooling the aerosol.

The ventilation enhances the generation of visible heated volatilizedcomponents from the consumable when it is heated in use. The heatedvolatilized components are made visible by the process of cooling theheated volatilized components such that supersaturation of the heatedvolatilized components occurs. The heated volatilized components thenundergo droplet formation, otherwise known as nucleation, and eventuallythe size of the aerosol particles of the heated volatilized componentsincreases by further condensation of the heated volatilized componentsand by coagulation of newly formed droplets from the heated volatilizedcomponents.

In some cases, the ratio of the cool air to the sum of the heatedvolatilized components and the cool air, known as the ventilation ratio,is at least 15%. A ventilation ratio of 15% enables the heatedvolatilized components to be made visible by the method described above.The visibility of the heated volatilized components enables the user toidentify that the volatilized components have been generated and adds tothe sensory experience of the smoking experience.

In another example, the ventilation ratio is between 50% and 85% toprovide additional cooling to the heated volatilized components. In somecases, the ventilation ratio may be at least 60% or 65%.

Referring to FIGS. 1 and 2 , there are shown a partially cut-awaysection view and a perspective view of an example of anaerosol-generating consumable 101. The consumable 101 is adapted for usewith a device having a power source and a heater. The consumable 101 ofthis embodiment is particularly suitable for use with the device 51shown in FIGS. 5 to 7 , described below. In use, the consumable 101 maybe removably inserted into the device shown in FIG. 5 at an insertionpoint 20 of the device 51.

The consumable 101 of one example is in the form of a substantiallycylindrical rod that includes a body of aerosol-generating material 103and a filter assembly 105 in the form of a rod. The aerosol-generatingmaterial comprises the amorphous solid material described herein. Insome embodiments, it may be included in sheet form. In some embodimentsit may be included in the form of a shredded sheet. In some embodiments,the aerosol-generating material described herein may be incorporated insheet form and in shredded form.

The filter assembly 105 includes three segments, a cooling segment 107,a filter segment 109 and a mouth end segment 111. The consumable 101 hasa first end 113, also known as a mouth end or a proximal end and asecond end 115, also known as a distal end. The body ofaerosol-generating material 103 is located towards the distal end 115 ofthe consumable 101. In one example, the cooling segment 107 is locatedadjacent the body of aerosol-generating material 103 between the body ofaerosol generating material 103 and the filter segment 109, such thatthe cooling segment 107 is in an abutting relationship with theaerosol-generating material 103 and the filter segment 103. In otherexamples, there may be a separation between the body ofaerosol-generating material 103 and the cooling segment 107 and betweenthe body of aerosol-generating material 103 and the filter segment 109.The filter segment 109 is located in between the cooling segment 107 andthe mouth end segment 111. The mouth end segment 111 is located towardsthe proximal end 113 of the consumable 101, adjacent the filter segment109. In one example, the filter segment 109 is in an abuttingrelationship with the mouth end segment 111. In one embodiment, thetotal length of the filter assembly 105 is between 37 mm and 45 mm, morepreferably, the total length of the filter assembly 105 is 41 mm.

In one example, the rod of aerosol-generating material 103 is between 34mm and 50 mm in length, suitably between 38 mm and 46 mm in length,suitably 42 mm in length.

In one example, the total length of the consumable 101 is between 71 mmand 95 mm, suitably between 79 mm and 87 mm, suitably 83 mm.

An axial end of the body of aerosol-generating material 103 is visibleat the distal end 115 of the consumable 101. However, in otherembodiments, the distal end 115 of the consumable 101 may comprise anend member (not shown) covering the axial end of the body ofaerosol-generating material 103.

The body of aerosol-generating material 103 is joined to the filterassembly 105 by annular tipping paper (not shown), which is locatedsubstantially around the circumference of the filter assembly 105 tosurround the filter assembly 105 and extends partially along the lengthof the body of aerosol-generating material 103. In one example, thetipping paper is made of 58GSM standard tipping base paper. In oneexample the tipping paper has a length of between 42 mm and 50 mm,suitably of 46 mm.

In one example, the cooling segment 107 is an annular tube and islocated around and defines an air gap within the cooling segment. Theair gap provides a chamber for heated volatilized components generatedfrom the body of aerosol-generating material 103 to flow. The coolingsegment 107 is hollow to provide a chamber for aerosol accumulation yetrigid enough to withstand axial compressive forces and bending momentsthat might arise during manufacture and whilst the consumable 101 is inuse during insertion into the device 51. In one example, the thicknessof the wall of the cooling segment 107 is approximately 0.29 mm.

The cooling segment 107 provides a physical displacement between theaerosol-generating material 103 and the filter segment 109. The physicaldisplacement provided by the cooling segment 107 will provide a thermalgradient across the length of the cooling segment 107. In one examplethe cooling segment 107 is configured to provide a temperaturedifferential of at least 40 degrees Celsius between a heated volatilizedcomponent entering a first end of the cooling segment 107 and a heatedvolatilized component exiting a second end of the cooling segment 107.In one example the cooling segment 107 is configured to provide atemperature differential of at least 60 degrees Celsius between a heatedvolatilized component entering a first end of the cooling segment 107and a heated volatilized component exiting a second end of the coolingsegment 107. This temperature differential across the length of thecooling element 107 protects the temperature sensitive filter segment109 from the high temperatures of the aerosol-generating material 103when it is heated by the device 51. If the physical displacement was notprovided between the filter segment 109 and the body ofaerosol-generating material 103 and the heating elements of the device51, then the temperature sensitive filter segment may 109 become damagedin use, so it would not perform its required functions as effectively.

In one example the length of the cooling segment 107 is at least 15 mm.In one example, the length of the cooling segment 107 is between 20 mmand 30 mm, more particularly 23 mm to 27 mm, more particularly 25 mm to27 mm, suitably 25 mm.

The cooling segment 107 is made of paper, which means that it iscomprised of a material that does not generate compounds of concern, forexample, toxic compounds when in use adjacent to the heater of thedevice 51. In one example, the cooling segment 107 is manufactured froma spirally wound paper tube which provides a hollow internal chamber yetmaintains mechanical rigidity. Spirally wound paper tubes are able tomeet the tight dimensional accuracy requirements of high-speedmanufacturing processes with respect to tube length, outer diameter,roundness and straightness.

In another example, the cooling segment 107 is a recess created fromstiff plug wrap or tipping paper. The stiff plug wrap or tipping paperis manufactured to have a rigidity that is sufficient to withstand theaxial compressive forces and bending moments that might arise duringmanufacture and whilst the consumable 101 is in use during insertioninto the device 51.

The filter segment 109 may be formed of any filter material sufficientto remove one or more volatilized compounds from heated volatilizedcomponents from the aerosol-generating material. In one example thefilter segment 109 is made of a mono-acetate material, such as celluloseacetate. The filter segment 109 provides cooling andirritation-reduction from the heated volatilized components withoutdepleting the quantity of the heated volatilized components to anunsatisfactory level for a user.

In some embodiments, a capsule (not illustrated) may be provided infilter segment 109. It may be disposed substantially centrally in thefilter segment 109, both across the filter segment 109 diameter andalong the filter segment 109 length. In other cases, it may be offset inone or more dimension. The capsule may in some cases, where present,contain a volatile component such as a flavorant or aerosol generatingagent.

The density of the cellulose acetate tow material of the filter segment109 controls the pressure drop across the filter segment 109, which inturn controls the draw resistance of the consumable 101. Therefore, theselection of the material of the filter segment 109 is important incontrolling the resistance to draw of the consumable 101. In addition,the filter segment performs a filtration function in the consumable 101.

In one example, the filter segment 109 is made of a 8Y15 grade of filtertow material, which provides a filtration effect on the heatedvolatilized material, whilst also reducing the size of condensed aerosoldroplets which result from the heated volatilized material.

The presence of the filter segment 109 provides an insulating effect byproviding further cooling to the heated volatilized components that exitthe cooling segment 107. This further cooling effect reduces the contacttemperature of the user's lips on the surface of the filter segment 109.

In one example, the filter segment 109 is between 6 mm to 10 mm inlength, suitably 8 mm.

The mouth end segment 111 is an annular tube and is located around anddefines an air gap within the mouth end segment 111. The air gapprovides a chamber for heated volatilized components that flow from thefilter segment 109. The mouth end segment 111 is hollow to provide achamber for aerosol accumulation yet rigid enough to withstand axialcompressive forces and bending moments that might arise duringmanufacture and whilst the consumable is in use during insertion intothe device 51. In one example, the thickness of the wall of the mouthend segment 111 is approximately 0.29 mm. In one example, the length ofthe mouth end segment 111 is between 6 mm to 10 mm, suitably 8 mm.

The mouth end segment 111 may be manufactured from a spirally woundpaper tube which provides a hollow internal chamber yet maintainscritical mechanical rigidity. Spirally wound paper tubes are able tomeet the tight dimensional accuracy requirements of high-speedmanufacturing processes with respect to tube length, outer diameter,roundness and straightness.

The mouth end segment 111 provides the function of preventing any liquidcondensate that accumulates at the exit of the filter segment 109 fromcoming into direct contact with a user.

It should be appreciated that, in one example, the mouth end segment 111and the cooling segment 107 may be formed of a single tube and thefilter segment 109 is located within that tube separating the mouth endsegment 111 and the cooling segment 107.

Referring to FIGS. 3 and 4 , there are shown a partially cut-awaysection and perspective views of an example of an consumable 301. Thereference signs shown in FIGS. 3 and 4 are equivalent to the referencesigns shown in FIGS. 1 and 2 , but with an increment of 200.

In the example of the consumable 301 shown in FIGS. 3 and 4 , aventilation region 317 is provided in the consumable 301 to enable airto flow into the interior of the consumable 301 from the exterior of theconsumable 301. In one example the ventilation region 317 takes the formof one or more ventilation holes 317 formed through the outer layer ofthe consumable 301. The ventilation holes may be located in the coolingsegment 307 to aid with the cooling of the consumable 301. In oneexample, the ventilation region 317 comprises one or more rows of holes,and preferably, each row of holes is arranged circumferentially aroundthe consumable 301 in a cross-section that is substantiallyperpendicular to a longitudinal axis of the consumable 301.

In one example, there are between one to four rows of ventilation holesto provide ventilation for the consumable 301. Each row of ventilationholes may have between 12 to 36 ventilation holes 317. The ventilationholes 317 may, for example, be between 100 to 500 μm in diameter. In oneexample, an axial separation between rows of ventilation holes 317 isbetween 0.25 mm and 0.75 mm, suitably 0.5 mm.

In one example, the ventilation holes 317 are of uniform size. Inanother example, the ventilation holes 317 vary in size. The ventilationholes can be made using any suitable technique, for example, one or moreof the following techniques: laser technology, mechanical perforation ofthe cooling segment 307 or pre-perforation of the cooling segment 307before it is formed into the consumable 301. The ventilation holes 317are positioned so as to provide effective cooling to the consumable 301.

In one example, the rows of ventilation holes 317 are located at least11 mm from the proximal end 313 of the consumable, suitably between 17mm and 20 mm from the proximal end 313 of the consumable 301. Thelocation of the ventilation holes 317 is positioned such that user doesnot block the ventilation holes 317 when the consumable 301 is in use.

Providing the rows of ventilation holes between 17 mm and 20 mm from theproximal end 313 of the consumable 301 enables the ventilation holes 317to be located outside of the device 51, when the consumable 301 is fullyinserted in the device 51, as can be seen in FIGS. 6 and 7 . By locatingthe ventilation holes outside of the device, non-heated air is able toenter the consumable 301 through the ventilation holes from outside thedevice 51 to aid with the cooling of the consumable 301.

The length of the cooling segment 307 is such that the cooling segment307 will be partially inserted into the device 51, when the consumable301 is fully inserted into the device 51. The length of the coolingsegment 307 provides a first function of providing a physical gapbetween the heater arrangement of the device 51 and the heat sensitivefilter arrangement 309, and a second function of enabling theventilation holes 317 to be located in the cooling segment, whilst alsobeing located outside of the device 51, when the consumable 301 is fullyinserted into the device 51. As can be seen from FIGS. 6 and 7 , themajority of the cooling element 307 is located within the device 51.However, there is a portion of the cooling element 307 that extends outof the device 51. It is in this portion of the cooling element 307 thatextends out of the device 51 in which the ventilation holes 317 arelocated.

Referring now to FIGS. 5 to 7 in more detail, there is shown an exampleof a device 51 arranged to heat aerosol-generating material tovolatilize at least one component of said aerosol-generating material,typically to form an aerosol which can be inhaled. The device 51 is aheating device which releases compounds by heating, but not burning, theaerosol-generating material.

A first end 53 is sometimes referred to herein as the mouth or proximalend 53 of the device 51 and a second end 55 is sometimes referred toherein as the distal end 55 of the device 51. The device 51 has anon/off button 57 to allow the device 51 as a whole to be switched on andoff as desired by a user.

The device 51 comprises a housing 59 for locating and protecting variousinternal components of the device 51. In the example shown, the housing59 comprises a uni-body sleeve 11 that encompasses the perimeter of thedevice 51, capped with a top panel 17 which defines generally the ‘top’of the device 51 and a bottom panel 19 which defines generally the‘bottom’ of the device 51. In another example the housing comprises afront panel, a rear panel and a pair of opposite side panels in additionto the top panel 17 and the bottom panel 19.

The top panel 17 and/or the bottom panel 19 may be removably fixed tothe uni-body sleeve 11, to permit easy access to the interior of thedevice 51, or may be “permanently” fixed to the uni-body sleeve 11, forexample to deter a user from accessing the interior of the device 51. Inan example, the panels 17 and 19 are made of a plastics material,including for example glass-filled nylon formed by injection moulding,and the uni-body sleeve 11 is made of aluminum, though other materialsand other manufacturing processes may be used.

The top panel 17 of the device 51 has an opening 20 at the mouth end 53of the device 51 through which, in use, the consumable 101, 301including the aerosol-generating material may be inserted into thedevice 51 and removed from the device 51 by a user.

The housing 59 has located or fixed therein a heater arrangement 23,control circuitry 25 and a power source 27. In this example, the heaterarrangement 23, the control circuitry 25 and the power source 27 arelaterally adjacent (that is, adjacent when viewed from an end), with thecontrol circuitry 25 being located generally between the heaterarrangement 23 and the power source 27, though other locations arepossible.

The control circuitry 25 may include a controller, such as amicroprocessor arrangement, configured and arranged to control theheating of the aerosol-generating material in the consumable 101, 301 asdiscussed further below.

The power source 27 may be for example a battery, which may be arechargeable battery or a non-rechargeable battery. Examples of suitablebatteries include for example a lithium-ion battery, a nickel battery(such as a nickel-cadmium battery), an alkaline battery and/or the like.The battery 27 is electrically coupled to the heater arrangement 23 tosupply electrical power when required and under control of the controlcircuitry 25 to heat the aerosol-generating material in the consumable(as discussed, to volatilize the aerosol-generating material withoutcausing the aerosol-generating material to burn).

An advantage of locating the power source 27 laterally adjacent to theheater arrangement 23 is that a physically large power source 25 may beused without causing the device 51 as a whole to be unduly lengthy. Aswill be understood, in general a physically large power source 25 has ahigher capacity (that is, the total electrical energy that can besupplied, often measured in Amp-hours or the like) and thus the batterylife for the device 51 can be longer.

In one example, the heater arrangement 23 is generally in the form of ahollow cylindrical tube, having a hollow interior heating chamber 29into which the consumable 101, 301 comprising the aerosol-generatingmaterial is inserted for heating in use. Different arrangements for theheater arrangement 23 are possible. For example, the heater arrangement23 may comprise a single heating element or may be formed of pluralheating elements aligned along the longitudinal axis of the heaterarrangement 23. The or each heating element may be annular or tubular,or at least part-annular or part-tubular around its circumference. In anexample, the or each heating element may be a thin film heater. Inanother example, the or each heating element may be made of a ceramicsmaterial. Examples of suitable ceramics materials include alumina andaluminum nitride and silicon nitride ceramics, which may be laminatedand sintered. Other heating arrangements are possible, including forexample inductive heating, infrared heater elements, which heat byemitting infrared radiation, or resistive heating elements formed by forexample a resistive electrical winding.

In one particular example, the heater arrangement 23 is supported by astainless steel support tube and comprises a polyimide heating element.The heater arrangement 23 is dimensioned so that substantially the wholeof the body of aerosol-generating material 103, 303 of the consumable101, 301 is inserted into the heater arrangement 23 when the consumable101, 301 is inserted into the device 51.

The or each heating element may be arranged so that selected zones ofthe aerosol-generating material can be independently heated, for examplein turn (over time, as discussed above) or together (simultaneously) asdesired.

The heater arrangement 23 in this example is surrounded along at leastpart of its length by a thermal insulator 31. The insulator 31 helps toreduce heat passing from the heater arrangement 23 to the exterior ofthe device 51. This helps to keep down the power requirements for theheater arrangement 23 as it reduces heat losses generally. The insulator31 also helps to keep the exterior of the device 51 cool duringoperation of the heater arrangement 23. In one example, the insulator 31may be a double-walled sleeve which provides a low pressure regionbetween the two walls of the sleeve. That is, the insulator 31 may befor example a “vacuum” tube, i.e. a tube that has been at leastpartially evacuated so as to minimize heat transfer by conduction and/orconvection. Other arrangements for the insulator 31 are possible,including using heat insulating materials, including for example asuitable foam-type material, in addition to or instead of adouble-walled sleeve.

The housing 59 may further comprises various internal support structures37 for supporting all internal components, as well as the heatingarrangement 23.

The device 51 further comprises a collar 33 which extends around andprojects from the opening 20 into the interior of the housing 59 and agenerally tubular chamber 35 which is located between the collar 33 andone end of the vacuum sleeve 31. The chamber 35 further comprises acooling structure 35 f, which in this example, comprises a plurality ofcooling fins 35 f spaced apart along the outer surface of the chamber35, and each arranged circumferentially around outer surface of thechamber 35. There is an air gap 36 between the hollow chamber 35 and theconsumable 101, 301 when it is inserted in the device 51 over at leastpart of the length of the hollow chamber 35. The air gap 36 is aroundall of the circumference of the consumable 101, 301 over at least partof the cooling segment 307.

The collar 33 comprises a plurality of ridges 60 arrangedcircumferentially around the periphery of the opening 20 and whichproject into the opening 20. The ridges 60 take up space within theopening 20 such that the open span of the opening 20 at the locations ofthe ridges 60 is less than the open span of the opening 20 at thelocations without the ridges 60. The ridges 60 are configured to engagewith an consumable 101, 301 inserted into the device to assist insecuring it within the device 51. Open spaces (not shown in the Figures)defined by adjacent pairs of ridges 60 and the consumable 101, 301 formventilation paths around the exterior of the consumable 101, 301. Theseventilation paths allow hot vapors that have escaped from the consumable101, 301 to exit the device 51 and allow cooling air to flow into thedevice 51 around the consumable 101, 301 in the air gap 36.

In operation, the consumable 101, 301 is removably inserted into aninsertion point 20 of the device 51, as shown in FIGS. 5 to 7 .Referring particularly to FIG. 6 , in one example, the body ofaerosol-generating material 103, 303, which is located towards thedistal end 115, 315 of the consumable 101, 301, is entirely receivedwithin the heater arrangement 23 of the device 51. The proximal end 113,313 of the consumable 101, 301 extends from the device 51 and acts as amouthpiece assembly for a user.

In operation, the heater arrangement 23 will heat the consumable 101,301 to volatilize at least one component of the aerosol-generatingmaterial from the body of aerosol-generating material 103, 303.

The primary flow path for the heated volatilized components from thebody of aerosol-generating material 103, 303 is axially through theconsumable 101, 301, through the chamber inside the cooling segment 107,307, through the filter segment 109, 309, through the mouth end segment111, 313 to the user. In one example, the temperature of the heatedvolatilized components that are generated from the body of aerosolgenerating material is between 60° C. and 250° C., which may be abovethe acceptable inhalation temperature for a user. As the heatedvolatilized component travels through the cooling segment 107, 307, itwill cool and some volatilized components will condense on the innersurface of the cooling segment 107, 307.

In the examples of the consumable 301 shown in FIGS. 3 and 4 , cool airwill be able to enter the cooling segment 307 via the ventilation holes317 formed in the cooling segment 307. This cool air will mix with theheated volatilized components to provide additional cooling to theheated volatilized components.

Exemplary Process

With reference to FIG. 8 , an exemplary method 800 of the inventioncomprises forming a layer of slurry 801. The forming a layer 801comprises preparing the slurry by mixing 26 wt % of alginate; 16 wt % ofglycerol; 38 wt % of menthol and 20 wt % of woodpulp (wherein theseweights are calculated on a dry weight basis) with water 801. Theforming a layer 801 further comprises casting the slurry as a layerapproximately 2 mm thick 801. The layer of slurry is sprayed with asolution of calcium lactate to accelerate setting of the alginate whichforms a gel.

The method further comprises drying the layer of slurry to form a sheetof amorphous solid 802. In some examples of the method 800, the methodcomprises cutting the sheet of amorphous solid into flags 803 forstorage and/or transport, or winding the sheet of amorphous solid onto abobbin 803 for storage and/or transport. In other examples of the method800, the method 800 does not comprise a cutting or winding 803 afterdrying 802.

In examples where the method 800 comprises winding the sheet ofamorphous solid onto a bobbin 803, the method further comprisesunwinding the amorphous solid sheet from the bobbin 804.

The method 800 further comprises shredding the amorphous solid sheet805. In examples of the method 800 which comprise unwinding theamorphous solid sheet from the bobbin 804, the bobbin is unwound by theshredding of the amorphous solid sheet 805 (e.g. the bobbin is unwoundas the sheet is fed into the shredder). The shredding of the sheet ofamorphous solid 805 carried out as described elsewhere herein. After theshredding 805, in some examples the method 800 comprises mixing theshredded amorphous solid with a shredded tobacco material andincorporating the mixture into a rod consumable 806.

Definitions

Active Substance

In some embodiments, the substance to be delivered comprises an activesubstance.

The active substance as used herein may be a physiologically activematerial, which is a material intended to achieve or enhance aphysiological response. The active substance may for example be selectedfrom nutraceuticals, nootropics, psychoactives. The active substance maybe naturally occurring or synthetically obtained. The active substancemay comprise for example nicotine, caffeine, taurine, theine, vitaminssuch as B6 or B12 or C, melatonin, cannabinoids, or constituents,derivatives, or combinations thereof. The active substance may compriseone or more constituents, derivatives or extracts of tobacco, cannabisor another botanical.

In some embodiments, the active substance comprises nicotine. In someembodiments, the active substance comprises caffeine, melatonin orvitamin B12.

Botanicals

As noted herein, the active substance may comprise or be derived fromone or more botanicals or constituents, derivatives or extracts thereof.As used herein, the term “botanical” includes any material derived fromplants including, but not limited to, extracts, leaves, bark, fibers,stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like.Alternatively, the material may comprise an active compound naturallyexisting in a botanical, obtained synthetically. The material may be inthe form of liquid, gas, solid, powder, dust, crushed particles,granules, pellets, shreds, strips, sheets, or the like. Examplebotanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis,fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax,ginger, Ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice),matcha, mate, orange skin, papaya, rose, sage, tea such as green tea orblack tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bayleaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary,saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla,wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro,bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace,damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena,tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca,ashwagandha, damiana, guarana, chlorophyll, baobab or any combinationthereof. The mint may be chosen from the following mint varieties:Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Menthapiperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa,Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata,Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

In some embodiments, the active substance comprises or is derived fromone or more botanicals or constituents, derivatives or extracts thereofand the botanical is tobacco.

In some embodiments, the active substance comprises or derived from oneor more botanicals or constituents, derivatives or extracts thereof andthe botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or derived from oneor more botanicals or constituents, derivatives or extracts thereof andthe botanical is selected from rooibos and fennel.

Flavors

In some embodiments, the substance to be delivered comprises a flavor.

As used herein, the terms “flavor” and “flavorant” refer to materialswhich, where local regulations permit, may be used to create a desiredtaste, aroma or other somatosensorial sensation in a product for adultconsumers. They may include naturally occurring flavor materials,botanicals, extracts of botanicals, synthetically obtained materials, orcombinations thereof (e.g., tobacco, cannabis, licorice (liquorice),hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile,fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed(anise), cinnamon, turmeric, Indian spices, Asian spices, herb,wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange,mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape,durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits,Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint,peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg,sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honeyessence, rose oil, vanilla, lemon oil, orange oil, orange blossom,cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage,fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil fromany species of the genus Mentha, eucalyptus, star anise, cocoa,lemongrass, rooibos, flax, Ginkgo biloba, hazel, hibiscus, laurel, mate,orange skin, rose, tea such as green tea or black tea, thyme, juniper,elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary,saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle,cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm,lemon basil, chive, carvi, verbena, tarragon, limonene, thymol,camphene), flavor enhancers, bitterness receptor site blockers,sensorial receptor site activators or stimulators, sugars and/or sugarsubstitutes (e.g., sucralose, acesulfame potassium, aspartame,saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol,or mannitol), and other additives such as charcoal, chlorophyll,minerals, botanicals, or breath freshening agents. They may beimitation, synthetic or natural ingredients or blends thereof. They maybe in any suitable form, for example, liquid such as an oil, solid suchas a powder, or gas.

In some embodiments, the flavor comprises menthol, spearmint and/orpeppermint. In some embodiments, the flavor comprises flavor componentsof cucumber, blueberry, citrus fruits and/or redberry. In someembodiments, the flavor comprises eugenol. In some embodiments, theflavor comprises flavor components extracted from tobacco. In someembodiments, the flavor comprises flavor components extracted fromcannabis.

In some embodiments, the flavor may comprise a sensate, which isintended to achieve a somatosensorial sensation which are usuallychemically induced and perceived by the stimulation of the fifth cranialnerve (trigeminal nerve), in addition to or in place of aroma or tastenerves, and these may include agents providing heating, cooling,tingling, numbing effect. A suitable heat effect agent may be, but isnot limited to, vanillyl ethyl ether and a suitable cooling agent maybe, but not limited to eucolyptol, WS-3.

Aerosol-Generating Material

Aerosol-generating material is a material that is capable of generatingaerosol, for example when heated, irradiated or energized in any otherway. Aerosol-generating material may, for example, be in the form of asolid, liquid or gel which may or may not contain an active substanceand/or flavorant. In some embodiments, the aerosol-generating materialmay comprise an “amorphous solid”, which may alternatively be referredto as a “monolithic solid” (i.e. non-fibrous). In some embodiments, theamorphous solid may be a dried gel. The amorphous solid is a solidmaterial that may retain some fluid, such as liquid, within it. In someembodiments, the aerosol-generating material may for example comprisefrom about 50 wt %, 60 wt % or 70 wt % of amorphous solid, to about 90wt %, 95 wt % or 100 wt % of amorphous solid.

The aerosol-generating material may comprise one or more activesubstances and/or flavors, one or more aerosol-former materials, andoptionally one or more other functional material.

Aerosol-Former Material

The aerosol-former material may comprise one or more constituentscapable of forming an aerosol. In some embodiments, the aerosol-formermaterial may comprise one or more of glycerine, glycerol, propyleneglycol, diethylene glycol, triethylene glycol, tetraethylene glycol,1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyllaurate, a diethyl suberate, triethyl citrate, triacetin, a diacetinmixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, laurylacetate, lauric acid, myristic acid, and propylene carbonate.

Consumable

A consumable is an article comprising or consisting ofaerosol-generating material, part or all of which is intended to beconsumed during use by a user. A consumable may comprise one or moreother components, such as an aerosol-generating material storage area,an aerosol-generating material transfer component, an aerosol generationarea, a housing, a wrapper, a mouthpiece, a filter and/or anaerosol-modifying agent. A consumable may also comprise an aerosolgenerator, such as a heater, that emits heat to cause theaerosol-generating material to generate aerosol in use. The heater may,for example, comprise combustible material, a material heatable byelectrical conduction, or a susceptor.

Aerosol Generator

An aerosol generator is an apparatus configured to cause aerosol to begenerated from the aerosol-generating material. In some embodiments, theaerosol generator is a heater configured to subject theaerosol-generating material to heat energy, so as to release one or morevolatiles from the aerosol-generating material to form an aerosol. Insome embodiments, the aerosol generator is configured to cause anaerosol to be generated from the aerosol-generating material withoutheating. For example, the aerosol generator may be configured to subjectthe aerosol-generating material to one or more of vibration, increasedpressure, or electrostatic energy.

EXAMPLES Example 1

Two amorphous solids (A and B) were prepared by forming a slurry ofmenthol, glycerol and alginate according to Table 1 below. Into slurryB, 20% by weight of fibers was added, and no fibers were added to slurryA. Both slurries were formed into a layer and sprayed with calciumlactate solution. The layers of slurry were dried to form a sheet ofamorphous solid A and a sheet of amorphous solid B. The only differencebetween amorphous solids A and B was that amorphous solid B contained20% by weight of fibers. The sheets were cut into flags for transport(6×6 cm squares).

TABLE 1 Component Amorphous Solid A Amorphous Solid B Menthol (wt %) 4838.4 Glycerol (wt %) 19.2 15.4 Alginate (wt %) 32.8 26.2 Fibers(woodpulp) (wt %) 0 20 Calcium Lactate spray (wt %) 4.5 4.5

When the flags of amorphous solid A arrived at their destination theflags had compressed/compacted down. Consequently, they had to be prisedapart in order to be shredded. When shredding the flags of amorphoussolid A, the sheets were tacky and stuck in the shredder causingblockages in the machinery. Once the amorphous solid A sheet wasshredded it was blended with shredded tobacco material and added toconsumables in the form of rods. However, the shreds of amorphous solidA tended to agglomerate (clump together); this meant that the mentholvariability in the rods was very high: some rods contained clumps ofamorphous solid, and other rods contained no amorphous solid.

By contrast, the flags of amorphous solid B (containing fibers) did nothave to be prised apart. Furthermore, the sheets could be shreddedeasily without causing blockages in the shredder machinery. The shreddedamorphous solid B was not observed to form clumps and could be blendedhomogeneously with shredded tobacco material to form rod consumableswhich had even distribution of the amorphous solid shreds. The onlydifference between the formulations A and B was the addition of 20%fibers to the amorphous solid formulation, demonstrating that use offibers can improve handling of the amorphous solid and result inimproved distribution of the amorphous solid shreds when these are addedto rod consumables.

All percentages by weight described herein (denoted wt %) are calculatedon a dry weight basis, unless explicitly stated otherwise. All weightratios are also calculated on a dry weight basis. A weight quoted on adry weight basis refers to the whole of the extract or slurry ormaterial, other than the water, and may include components which bythemselves are liquid at room temperature and pressure, such asglycerol. Conversely, a weight percentage quoted on a wet weight basisrefers to all components, including water.

For the avoidance of doubt, where in this specification the term“comprises” is used in defining the invention or features of theinvention, embodiments are also disclosed in which the invention orfeature can be defined using the terms “consists essentially of” or“consists of” in place of “comprises”. Reference to a material“comprising” certain features means that those features are included in,contained in, or held within the material.

The above embodiments are to be understood as illustrative examples ofthe invention. Further embodiments of the invention are envisaged. It isto be understood that any feature described in relation to any oneembodiment may be used alone, or in combination with other featuresdescribed, and may also be used in combination with one or more featuresof any other of the embodiments, or any combination of any other of theembodiments. Furthermore, equivalents and modifications not describedabove may also be employed without departing from the scope of theinvention, which is defined in the accompanying claims.

1. A method of manufacturing an aerosol-generating material comprising ashredded amorphous solid, the method comprising: a) forming a layer of aslurry comprising: 1-60 wt % of a gelling agent; 0.1-50 wt % of anaerosol-former material; 5-50 wt % of filler in the form of fibers; and0.1-80 wt % of a flavorant and/or active substance;  wherein theseweights are calculated on a dry weight basis, b) drying the slurry toprovide the amorphous solid; and c) shredding the amorphous solid toprovide the shredded amorphous solid.
 2. The method according to claim 1wherein the fibers comprise wood fibers.
 3. The method according toclaim 1 wherein the flavorant is menthol.
 4. The method according to anyof claim 1, wherein the gelling agent comprises a hydrocolloid.
 5. Themethod according to any of claim 1, wherein the gelling agent comprisesone or more compounds selected from the group comprising alginates,cellulose derivatives, gums, silica or silicones compounds, clays andcombinations thereof.
 6. The method according to any of claim 1, whereinthe gelling agent comprises a calcium-crosslinked alginate and/or acalcium-crosslinked pectin.
 7. An aerosol-generating material comprisingan amorphous solid, wherein the amorphous solid comprises: 1-60 wt % ofa gelling agent; 0.1-50 wt % of an aerosol-former material; 5-50% offiller in the form of fibers; and 0.1-80 wt % of a flavorant and/oractive substance, wherein these weights are calculated on a dry weightbasis, wherein the amorphous solid is in the form of shreds.
 8. Theaerosol-generating material according to claim 7 wherein the amorphoussolid is in the form of shredded sheet.
 9. The aerosol-generatingmaterial according to claim 7, wherein the fibers comprise wood fibers.10. The aerosol-generating material according to any of claim 7, whereinthe flavorant is menthol.
 11. The aerosol-generating material accordingto any of claim 7, wherein the gelling agent comprises a hydrocolloid.12. The aerosol-generating material according to any of claim 7, whereinthe gelling agent comprises one or more compounds selected from thegroup comprising alginates, cellulose derivatives, gums, silica orsilicones compounds, clays and combinations thereof.
 13. Theaerosol-generating material according to any of claim 7, wherein thegelling agent comprises a calcium-crosslinked alginate and/or acalcium-crosslinked pectin.
 14. The aerosol-generating materialaccording to any of claim 7, wherein the aerosol-generating materialcomprises shredded tobacco material blended with amorphous solid in theform of shreds.
 15. An aerosol-generating material obtainable by usingthe method defined in claim
 1. 16. A consumable for use with anon-combustible aerosol provision system, the consumable comprising theaerosol generating material as defined in claim
 7. 17. A non-combustibleaerosol provision system comprising the consumable as defined in claim16 and a non-combustible aerosol provision device, the non-combustibleaerosol provision device comprising an aerosol-generation devicearranged to generate aerosol from the consumable when the consumable isused with the non-combustible aerosol provision device.
 18. Use of anaerosol-generating material as defined in claim 7 in a consumable foruse with a non-combustible aerosol provision device, the non-combustibleaerosol provision device comprising an aerosol-generation devicearranged to generate aerosol from the consumable when the consumable isused with the non-combustible aerosol provision device.